Control means for cupola furnaces



June 22, 1948. w, QIBRIEN 2,443,960

CONTROL umus FOR cuPOLA FURNACES Filed March 9. 1944 2 Sheets-Sheet 1 TO ausr mm INVENTOR CURRENT WILLIAM A; O'BRIEN 45 By C ATTGPNEYS w. A. O'BRIEN CONTROL MEANS FOR CUPOLA FURNACES June 22, 1948.

2 Sheets-Sheet 2 Filed March 9} 1944 a i IL A l I 3 H H I m 8 2 LI 2 s 4 INVENTOR.

WILLIAM A-O'BRIEN I BY ,Z% M f ATIORAEYS Patented June 22 1948 UNITED STATES PATENT OFFICE CONTROL MEAN S FOR CUPOLA FURNACES William A. OBrien, Fostoria, Ohio Application March 9, 1944, Serial No. 525,686

Claims. 1

This invention relates to cupola furnaces, more particularly to the methods of controlling the output of cupola furnaces.

When ferrous metals are melted in a cupola furnace for the purpose of pouring castings, it is highly desirable that the temperature of the molten-metal may be controlled within relatively close limits. At the same time it is highly desirable that the level of the molten metal in the cupola be known with sufiicient accuracy at the time the molten metal is withdrawn from the cupola into a pouring ladle, particularly with reference to the status of melting of the individual charges of metal dropped into the cupola from above. In general these charges of metal which are to be melted are alternated with charges of coke, each charge of metal and coke being carefully proportioned to give uniform melting conditions within the cupola. The charge of metal is usually made up of predetermined quantities of pig iron, scrap iron, which usually includes plant returns such as gates, bad castings, etc., and lastly steel scrap. The proportions of these constituents of the charge depend upon an analysis of the different iron forms so that the chemical constituents of the melted metal in the cupola may be capable of being controlled, particularly with reference to silicon and carbon.

These charges of metal and coke are dumped alternately into the cupola over a bed of coke, for example, the coke bed may comprise in a typical cupola, 3500 pounds of coke which is ignited to form the bed, then a charge of iron of approximately 2000 pounds is dumped which may constitute 800 pounds of pig iron, 1000 pounds of scrap iron and 200v pounds of steel scrap. Above this charge, a charge of coke of about 200 pounds is dumped, -and thereafter a second charge of metal is dumped into the cupola and so forth alternately metal and coke in the given proportions are dumped into the cupola until the desired level =is-obtained. The air blast is then injected into the-cupola to start the melting of the metal.

Inasmuch as the charge of metal consisting of the pig iron, scrap iron and scrap steel may not have the same physical characteristics so that melting occurs uniformly, this being particularly true when pieces of the various iron and steel are of 'various sizes and also due to the fact that steel has a much higher melting point than the pig or scrap iron, it is highly desirable that molten metal be withdrawn from the cupola during a period in which a charge 'of metal has just been completely melted and before the next succeeding charge of metal shall begin to melt. At this moltenmetal from the furnace after several of the iron charges have been fully melted so that an average physical and chemical condition may be obtained in the molten metal from the several metal charges which have been melted, which has a tendency of giving more uniform qualities both physically'and chemically to the molten metal as it issues from the cupola.

, An operator can, by controlling the characteristics of the metal dumped into the cupola, determine the melting conditions in the cupola with reasonable accuracy if he knows the level of the molten metal in the cupola, and this invention contemplates the provision of an electrical measuring system whereby an operator can determine the status of the melting conditions having reference to the individual metal charges. Knowing the chemical and physical characteristics of the molten metal within reasonable limits as it issues from the cupola, an operator can add addition ingredients to the molten metal, such as carbon, manganese, etc., to obtain the desired physical and chemical characteristics of the metal in the castings. If the characteristics of the basic melt are reasonably uniform, the amount of the addition ingredients for a given quantity of molten metal, such as the amount of metal me. full ladle, can be calculated with considerable accuracy to give a reasonable control over the characteristics of the metal in the final castings.

The present invention contemplates the provision of an electrical measuring system whereby the temperature of the molten metal in the furnace can be measured continuously and can be determined with reasonable accuracy before beginning a pour.

This invention further contemplates the provision of an electrical signalling system which is capable of giving a clear indication to an operator of the amount of molten metal which is available in a cupola furnace. The operator is then able to estimate the characteristics of the molten metal and is assured that there is always suillcient metal available to fill a ladle. Knowing the characteristics of the basic. melt he can calculate the quantitles of addition ingredients to be added to the molten metal to give the predetermined physical and chemical characteristics when the molten metal is poured into the molds to form castings.

The present invention further contemplates the provision of an additional signalling circuit to cooperate with the signalling system set forth in the previous paragraph which will giv semiautomatic control over the maximum level of molten metal in a cupola furnace. The air blast which is issuing from tuyres in the cupola, to provide the necessary temperature to melt the metal, is controlled" electrically and terminated when the level of molten metal reaches the maximum so that no further metal is melted until sufflcient molten metal is withdrawn .from the cupola to again give rise to conditions under which further melting of metal may take place. A cupola is generally provided with a sla hole which allows an operator to withdraw, from the surface of the molten'metal in the cupola, slag which is formed as a by-product of the melting operations and it is essential that this floating coating of slag shall be maintained over the molten metal to protect the metal from adverse conditions in the cupola. Should the level of molten metal rise until it reaches a level above the slag hole, the molten metal would flow from the furnace through the slag hole when it is opened by an operator. This would result in loss of metal and at the same time would allow cooling air currents to come in contact with the surface of the molten metal with deleterious effects. Furthermore, it is advantageous to control the level of the molten metal to maintain it at a point somewhat below the slag hole to prevent the floating slag from being carried upwardly into the tuyeres which would result in the blocking of the tuyeres and impeding the air blast and necessitating a shutdown of the furnace for a cleanout. The electrical system proyided for this purpose automatically terminates th air blast which reduces the temperature in the cupola to prevent further melting of metal. After the operator has withdraw a pour" from the furnace, the air blast may be again initiated at the volition of the operator, who is provided with a. manual overcontrol which must be actuated in order to start the blowers.

The invention further contemplates providing an installation in a cupola which will give continuous indications of temperature and/or level of the molten metal in a cupola furnace and at the same time will fully protect the instrumentalities by which these readings are obtained from adverse physical conditions in the cupola, which might cause breakage, slagging, etc. This result is obtained by the provision of an enclosed well formed in the wall of the cupola in which these sensitive instrumentalities are mounted, the well having an entry aperture adjacent its lower end wall in communication with the interior of the cupola so that the molten metal may readily flow into the well and seek its own level. In order to obviate undue cooling of the segregated molten metal in the well, the spout opening of the cupola is located in the exterior wall of the well substantially opposite the entry aperture so that molten metal which is drawn from the cupola must first pass through the well before it can flow into a ladle. This prevents stagnant molten metal from collecting in the well and,

inasmuch as the instrumentalities which are used to register the temperature and level of the molten metal are positioned in this well, more accurate readings may be obtained from the signalling and measuring circuits cooperating with these instrumentalities due to the fact that the molten metal which is in contact with them is being changed frequently as molten metal is withdrawn from the cupola.

It is, therefore, a principal object of this invention to provide electrical measuring instruments for a cupola furnace to indicate temperature and level of molten metal therein, the instrumentalities of these measuring instruments in contact with the molten metal being positioned in a protective well having communication with the cupola and with the spout opening.

It is a further object of this invention to provide a control means for a cupola which will shut 4 oil the air blast when the molten metal attains a predetermined level having a relation to the sla hole in the cupola.

It is a further object of this invention to provide a protective device for the instrumentalities of electrical measuring circuits in contact with molten metal in a cupola furnace which will prevent physical damage to these instrumentalities by movements of material within the cupola furnace during a heat.

It is a further object of this invention to provide electrical indicating circuits for a cupola furnace which will accurately register temperature and level of molten metal in a cupola furnace.

It is a further object of this invention to provide a protective well in the wall of a cupola furnace to house the instrumentalities of electrical measuring circuits for indicating temperature and level of molten metal in the cupola, themolten metal in the protective well being renewable by cooperating with the pouring spout of the cupola to assure uniform measuring conditions for the instrumentalities so that an accurate indication of temperature and level of the molten metal in the cupola may be observed by an attendant.

Other objects and advantages of this invention relating to the arrangement, operation and function of the related elements of the structure, to various details of construction. to combination of parts and to economics of manufacture, will be apparent to those skilled in the art upon consideration of the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several view:

Fig. 1 is an elevational view of a cupola furnace to which the invention has been applied.

Fig. 2 is a sectional elevation of the cupola furnace.

Fig. 3 is a sectional elevation of a portion of the cupola furnace, taken through the pouring vent.

Fig. 4 is an elevational view partly sectional, taken along the line 4-4 of Fig. 3.

Fig. 5 is a schematic diagram of connections.

Fig. 6 is a sectional view, taken along the line I 86 of Fig. 4.

Referring to" the drawings, particularly to Fig. 1, a cupola furnace I0 is shown supported on standard II to maintain a pouring trough i: a substantial distance above the floor to allow molten metal to be poured into a ladle l3. On the opposite side of the furnace a second trough I4 is provided to allow venting of slag from the furnace. Girdling the furnace is an air box IE which is in communication with a centrifugal blower l6 by means of an air duct II. The blower I6 is operated by an electric motor I8 which receives its power by leads i9 and 20. On the forward side of the furnace, preferably adjacent the pouring trough l2, a group of signal lights 2| are provided attached to the cupola by means of bracket 22 so as to be clearly visible to an operator. Immediately above the pouring trough the air box I5 is cut away and provided with a box-like construction 23 in which are mounted electrical instrumentalities which form a part of this invention.

Referring now to Fig. 2, the air box l5 girdles the furnace adjacent tuyres 24 which allow the air blast to issue into the interior of the furnace from the air box. As has already been pointed into the recess 36.

the cut away portion. The box 23 is preferably made of sheet metal and is provided with a hinged cover 2,6 to allow entry into the box for adjustment of, the electrical 'instrumentalities mounted therein and to be described in detail hereinafter. As is well known. in the art, floor 21 of the lcupola furnace is removable to allow repairs to the interior of the furnace after the completion of a days operation] Ordinarily in a foundry,

two of these cupola furnaces are provided, preferably positioned immediately adjacent each other to allow alternate use thereof, for example, if

furnace A is in operation, furnace B will be idle;

so that its floor may be removed and repairs made to its interior'so as to be ready for operation the following day. On'the following day the furnace B which has just been repaired is placed in operation while furnace A, which operated the previous day, has its floor removed and necessary repairs-made. In this way continuous operation of the foundry is made possible. A single control means is provided forboth furnaces and switching means are provided so that the control'means -may be usedwith either cupola and its signalling devices as' will be described in further detail hereinafter.

r The floor 2-! of the cupola furnace may comprise refractory sand or the like, supported in the usual manner to be readily removable, while the walls 28 of the furnace aremade of refractory brick positioned inside a metal envelope 28a as is most clearly shown in Fig. 3. With the floor 21 of the furnace removed; an operator is able to make necessary repairs to the interior surface of the furnace which in many cases is roughened by the action of the heat during operation of the furnace." In order to inst-all the instrumentalitles of this invention in the furnace, the operator cuts an aperture 29 (Fig. 4) which may begenerally of a rectangular contour, the base 39 of which is slightly below the level of'the sand floor 21 of the furnace while the upper terminus 3| of the aperture extends slightly above the level of a slag vent 32 which is preferably positioned diametrically opposite from the aperture 29 and cooperates with the trough 14 for the purpose of withdrawing slag from the interior of the furnace during operation. I

An open-ended box-like structure 33 is posi- 'tioned inthe aperture, being approximately of the same dimension, and cemented in place-by a fire-clay composition as is 'well known in the art. The box 33. is positioned in the aperture 29 1 with its open end exposed to the interior of the furnace and with itsforward edge 34 disposed slightlybehind the inner surface 35 of thecupola for. purposes which will be described hereinafter.

=The forward edge is provided with a'recess 36 which extends around three sides of the box and tcrminates'a slight distance above the lower side 31 of the box to form anabutment 33 against which rests a refractory cover 39 closely fitting The vertical dimension of the cover 39 issomewhat less than the dimension of the box so that a rectangular aperture 40 is formed between a lower terminus 4| of the cover 39 and the lower side 31 of the box. The

,coverl 39 is held in position in the recess 36 by means of a thick protective coating of cement 42 composed of fire-clay and other constituents as ,fis, well known in the art. The body of cement 42fi's positioned under the over-hangingof the tenor 36 of, the wall 26 so as to provide a A, 46 and 41 which will be described in detail into the interior of the box 33 comes in contact with electrical instrumentalities such as a temperature measuring device 44 and electrodes'45, 45A, 46 and 41, all of which are mounted in apertures 44a, 45a, 453, 46a and 41a, all in the side 46 of the box-like construction.

The portion of the electrical instrumentality 44 which projects into the interior of the'box-like enclosure through oblique aperture 44a may be a refractory tube sealed in the aperture 44a by means of refractory cements such as are well known in the art. Measuring devices 49 are provided cooperating with the refractory tube which may comprise optical pyrometers which are responsive to the temperature of the bottom 44b of the refractory tube and are placed in electrical circuit by means of conductors 59 which extend to indicating instruments, preferably located at a remote place from the cupola furnace. It is to be understood that any pyrometric device for measuring temperature or other conditions of the molten metal may be used in connection with the box-like enclosure.

The instrumentality 44, with its refractory tube, is held in aligned position with oblique aperture 44a by means of an oblique plate 5| which is conveniently attached to the metal shell 28a of the cupola and to a vertical plate 52 which forms the outside wall of a compartment 53 into which pro- J'ects the terminal ends of instrumentalities 45,

hereinafter. The refractory tube may be provided at its upper end with a collar 54 supported by the plate SI and to which measuring device 49 isattached by means of bolts 65.

The electrical instrumentalities 45, 45A, 46 and 41 are generally in the nature of electrodes, preferably being made of carbon rods, which are inserted in apertures in the side wall 43 of the boxlike enclosure as is most clearly shown in Fig. 6

with reference to electrode 46. The aperture 46a in the side wall 48 of the enclosure is tapering in form and considerably larger than the outside dimension of the electrode 46 which allows the positioning ofa body of refractory cement 66 to hold the electrode firmly in position inthe enclosure and to insulate the same electrically so that the electrode may be placed in an electric circuit by means of conductor 51 as most clearly shown in Fig. 3. The conductor 51 is connected to the electrode 46 by means of a clamping device 58. Electrodes 45, 45A, and 4'! are also provided with conductors, being connected to the body of the electrode in the same manner.

Inasmuch as the electrodes 45,- 45A, 46 and 41 are made of carbon, the tips of which are in contact with molten metal at a, very high temperature, it is obvious that the electrodes are subject to erosion and burning. A renewable tip 46b is therefore provided, which has a lug 460 which cooperates with a, kerf 46d so as to hold the tip 46b to the main body of the electrode. Inasmuch as the destruction of the tip 46b is reladay's exposure to the molten metal. These electrodes are placed in an electric circuit as will be described hereinafter.

- The electrode 45 is preferably positioned adjacent the bottom end 31 of the box-like enclosure forming a common ground terminal, while the electrodes 45A and 46 are positioned preferably adjacent the central portion of the box-like enclosure and the electrode 41 is preferably positioned near the upper end. The relative position of these electrodes may be varied to suit the conditions which an operator desires to indicate; for example, the relative position of the electrodes 45, 45A and 46 is determined by the amount of metalwhich an operator needs to fill a pouring ladle with a desirable margin to assure that the ladle, or the desired number of ladies, may be filled atone time. The relative relation between the electrodes 46 and 41 has a relation to a control for the blower i6 (Fig. 1) as driven by electric motor i8.

Should the level of the molten metal attain the datum of electrode 41, an electric circuit will be established which will break the power circuit to the motor iii to stop the blower it which will terminate the air blast which is being supplied to the cupola furnace through tuyeres 24. When the air blast stops, the temperature in the furnace will drop sothat the melting of metal stops and the level of the molten-metal will not be raised above the datum of the electrode 41. Signal lamps 21 may be used in connection with electrodes 45, 45A, 46 and 41 to indicate to an operator the level of the molten metal in the cupola to advise the operator whether or not there is sufllcient molten metal available in the furnace to fill the required number of ladies. The action of the electrodes, 45, 45A, 46 and 41 is such that an electric circuit is established when the molten metal comes into contact with the carbon tips 46b of the electrodes inasmuch as the molten metal is a good conductor of electricity.

The molten metal from the furnace enters the box-like enclosure 33 through aperture 40, as has already been described, and seeks its own level with reference to the level of molten metal in the interior of the furnace. Due to the fact that the molten metal in the enclosure is relatively isolated from the main body of the molten metal in the interior of the furnace, the heat losses due to radiation and conduction through the furnace walls causes a reduction in temperature of the molten metal in the enclosure so that the measuring devices, particularly the temperature indicating devices, will no longer give an accurate indication of the conditions of the molten metal in the interior of the furnace. In order to avoid these difficulties, this invention provides a means for renewing the molten metal in the enclosure to prevent stagnation which would result in inaccurate readings being recorded by the measuring lnstrumentalities. To attain this end, pouring vent 60 of the cupola is centrally positioned in the outer side Wall 48 of the enclosure 33; just above the level of the bottom 31, so that as molten metal is being drawn from the furnace, the molten metal in the enclosure will be subject to withdrawal first, at the moment the pouring vent B is opened at the outside of the cupola, by an operator in a manner well understood in the art.

A vent block SI of refractory material is provided, having an aperture Gin; aligned with the pouring vent 60 so as to lead the molten metal to the exterior of the furnace into the trough I! to issue into the pouring ladle IS. The vent 8 block BI is positioned on the floor of compartment 53, being held in position by means of refractory cement such as is commonly used in the art. In order to insulate and protect the terminal ends of the instrumentalities 45, 45A, 46 and .41, a filling of loose refractory material 82 is positioned in the compartment 53 between the vent block GI and the oblique plate ii.

When molten metal is withdrawn from the cupola furnace by an operator, the pouring vent 60 is opened at its outer end which allows the molten metal to issue from the cupola into the pouring ladle through the agency of the trough I2. The first metal to issue from the cupola furnace will proceed from the enclosure 33 to prevent the stagnation of metal in the enclosure. However, new metal will continuously pour into the enclosure through aperture 40 from the interior of the furnace to maintain its own level within the enclosure. Due to the fact that the size of aperture 40 between the interior of the enclosure and the interior of the furnace is many times greater than the pouring vent, the level of molten metal in the enclosure will not be subiii) stantially lower to createa difference between its level and the level of molten metal in the interior of the furnace. An accurate determination can therefore be attained both as to-the level of the molten metal in the interior of the furnace and also an accurate determination of the temperature of the molten metal due to the fact that the metal which comes in contact with the end 44b of the pyrometric device 44 is constantly being renewed from the interior of the furnace so that the temperature recorded by the measuring and indicating instruments cooperating with the pyrometric devicev will be an accurate reflection of the temperature of the molten metal in the interior of the furnace. -After the ladies have been filled, the operator will again close the outer end of the pouring vent to by means of plugger 63, the end of which is capped with a putty-like refractory body to close the pouring vent and stop the flow of molten metal.

The signalling means 2|, preferably comprising colored electric lights, cooperate with the electrodes 45, 45A, 46 and 41 and are connected as shown in the schematic diagram of connections in Fig. 5. Two sets of three lights are shown being preferably colored green, amber and red, although different arrangements may be used if desired, for example two lights may in many applications be adequate. As has already been pointed out, two cupola furnaces are generally used alternately, each being provided with a separate set of instrumentalities and signal lights as is clearly shown in the diagram of connections. Two four-pole double throw switches I54 and 65 are provided to manually control the instrumentalities of either cupola and to place them into electriccircuit with the relays 66 which, in turn, control the signal lamps of the individual cupola furnaces. One of the relays 66 controls the current to the motor I8 so as to controlthe air blast to the cupola when the level of molten metal approaches the datum of the electrode 41.

If the level of molten metal is allowed to reach the level of the slag hole, molten metal will be vented from the furnace by the slag hole 32 which iown temperature measuring devices, particuiarly those which operate upon an optical principle, may be utilized in this application and no description of the details of these measuring devices, or the electrical circuits with which they cooperate, is necessary for a man skilled in the art to understand the operation of this invention.

It is to be understood that the above detailed description of the present invention is intended to disclose an embodiment thereof to those skilled in the art, but that the invention is not to be construed as limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of being practiced and carried out in various ways without departing from the spirit of the invention. The language used in the specification relating to the operation and function of the elements of the invention is employed for purposes of description and not of limitation, and it is not intended to limit the scope of the following claims beyond the requirements of the prior art.

What is claimed:

1. In electrical measuring and control circuits .for cupola furnaces, electrical instrumentalities cooperating with the moltenmetal in the furnace to indicate temperature and level conditions of the molten metal, measuring and indicating devices cooperating with the electrical instrumentalities including a source of electrical energy to indicate the said condition of the molten metal, and control means cooperating with the air blast of the cupola furnace to control the air blast when the level of the molten metal attains a predetermined level.

2. In a cupola furnace having a pouring vent and an electrical blower to provide an air blast, a box-like enclosure in a wall of the cupola furnace in communication with the interior of the furnace adjacent the floor thereof at the level of the pouring vent to allow molten metal to seek its own level therein, electrical instrumentalities positioned in said enclosure in contact with the molten metal and responsive to the level of the molten metal, electrical circuits including a source of energy cooperating with said instrumentalities, indicating devices in said electrical circuits and cooperating with said electrical instrumentalities to indicate the level of the molten metal, and means cooperating with the pouring vent and the enclosure to renew the molten metal in the enclosure.

3. In a cupola furnace including a pouring vent, a slag vent and an electrical blower to provide an air blast, an enclosure in the wall of the cupola in communication with the interior of the furnace adjacent the floor thereof at the level of the pouring vent to allow the molten metal'to 10 indicating devices cooperating with said instrumentalities, and means also cooperating with said instrumentalities for terminating said air blast to the furnace when the level of the molten metal approaches the level of the slag vent.-

4. In a cupola furnace having pouring and slag vents and including electrical blower means for providing anair blast, an enclosure in the wall of the cupola in communication with the in-'' terior of the furnace adjacent the floor thereof at thelevel of the pouring vent to allow molten metalto seek its own level therein, said enclosure extending to a point above the level of the slag vent, instrumentalities positioned in said enclo-' sure in contact with the molten metal responsive to the level of the molten metal, electrical circuits including a source of electrical energy to cooperate with said instrumentalities, measuring and indicating devices cooperating with said instru mentalities and said electrical circuits to indicate wall of the cupola adjacent the floor with its open side in communication with the interior of the furnace, cover means for the open side of the enclosure having an aperture adjacent the floor of the cupola to place the interior of the enclosure in communication with the cupola,to allow molten metal to seek its own level therein,

' level,-

seek its own level in the enclosure, electrical instrumentalities positioned in said enclosure in contact with the molten metal and responsive to the level of the molten metal. measuring and electrical instrumentalities positioned in said enclosure, including liquid level indicating and measuring devices and a source of electrical energy, to indicate the level of the molten metal, means to maintain the temperature and liquid level condition of the molten metal in the enclosure in contact with the electrical instrumentalities substantially the same as the said conditions of the molten metal in the furnace, and means cooperating with the electrical instrumentalities to control the operation of the furnace when the level of the molten metal attains a predetermined WILLIAM A. O'BRIEN.

appearances orrnn The following references are of record in the file of this patent:

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